Copper-based PCB
Double-Sided Copper Core PCB Solutions for Automotive Manufacturing Automation
Item No.: Copper01
Leading Copper-based PCB manufacturer specializing in high-thermal-conductivity Metal Core PCBs. Customized solutions for power electronics, LED & automotive. Full EMS support.
Description
UltraTherm™ Copper Core PCBs represent a breakthrough in thermal management technology for modern electronics. As a specialized variant of Metal Core PCBs (MCPCBs), they utilize a solid copper substrate (1.0–5.0 mm thickness) instead of traditional aluminum or ceramic cores. This Copper-based design achieves thermal conductivity ratings up to 400 W/mK – nearly double that of aluminum alternatives – making it indispensable for applications demanding rapid heat dissipation.
The core structure comprises three optimized layers:
Copper Substrate (Base Layer): 99.8% pure copper for maximum heat transfer.
Dielectric Insulation: Ceramic-filled polymer layer (0.1–0.3 mm) withstanding >3kV breakdown voltage.
Circuit Layer: High-current copper traces (1–20 oz) for power integrity.
Double-Sided Copper Core PCB Solutions for Automotive Manufacturing Automation
Our customized services allow engineers to specify substrate thickness, dielectric properties, and surface finishes (ENIG/HASL/Immersion Silver). For complex projects, we offer Copper Based hybrid designs integrating FR4 sections for signal control. As a full-service EMS provider, we support every phase – from thermal simulation and DFM analysis to automated assembly and functional testing.
Copper Core PCBs excel in environments where thermal cycling (e.g., -50°C to +150°C) causes conventional PCBs to delaminate. The copper core’s low CTE (16–18 ppm/°C) closely matches ceramic components, reducing solder joint stress. Applications include:
High-brightness LED arrays (1000W/m²+)
EV battery management systems
RF power amplifiers (5G/radar)
Industrial motor drives
Superior Thermal Management
Copper’s thermal conductivity (385 W/mK) is 2x higher than aluminum, slashing hotspot temperatures by 30–50°C. This prevents LED lumen decay, IGBT derating, and electrolytic capacitor drying – critical for >100,000-hour lifespans.
Material Excellence
High Purity Copper: Oxygen-free copper (C10100/C10200) minimizes grain boundaries for uniform heat spreading.
Military-Grade Dielectrics: Thermal resistance as low as 0.15°C-in²/W (vs. 1.0+ for standard MCPCBs).
Mechanical Resilience: Copper’s tensile strength (210 MPa) withstands vibration/shock in automotive/aerospace.
Electrical Performance
Low-impedance power planes enable 500A+ current delivery.
RF-friendly substrates with Dk=3.0±0.1 up to 10 GHz.
Manufacturing Precision
Laser-drilled micro-vias (<100μm) for HDI designs.
±0.05mm layer-to-layer registration.
UL 94 V-0 flame-rated options.
Meidear PCB positions itself as an end-to-end PCB solutions provider specializing in high-performance metal-core boards. Key observations:
Core Competencies:
Metal Core PCB Focus: Heavy emphasis on Copper-based PCBs and aluminum substrates for LED, power electronics.
Vertical Integration: Offers design → fabrication → component sourcing → assembly (EMS) under one roof.
Customization Strength: Highlights customized services for unusual shapes, hybrid materials, and thermal solutions.
Content Strategy:
Technical blogs address thermal design challenges (e.g., "Solving LED Thermal Runaway").
Case studies target automotive/industrial clients.
Lacks detailed copper PCB datasheets – a missed opportunity for engineers.
Market Positioning:
Targets mid/high-volume B2B clients (min. order 50–100pcs).
Strong Chinese manufacturing base with global EMS support.
Could enhance value by adding:
Thermal simulation reports
Comparative aluminum vs. copper performance data
RoHS 3.0/REACH compliance documentation
1. High-Power LED Systems
Challenge: 1000W COB LEDs generate >150°C junction temperatures.
Solution: UltraTherm™ Copper Core PCBs reduce thermal resistance to 0.25°C/W, enabling:
20% higher luminous efficiency
50% longer lifespan vs. aluminum MCPCBs
Applications: Stadium lighting, horticultural grow lights, automotive headlamps.
2. Electric Vehicle Power Electronics
Challenge: IGBT inverters in EVs produce 500W/cm² heat flux.
Solution: Direct-bonded copper (DBC) substrates on Copper-based PCBs achieve:
40°C lower operating temperatures
15% higher power density
Applications: OBC chargers, traction motor controllers.
3. Industrial Power Supplies
Challenge: Server PSUs require 99.995% uptime at 80+ Amps.
Solution: 3.0mm Copper Core PCBs with 20oz copper layers:
Handle 120A continuous current
Survive 100,000+ thermal cycles
Applications: Telecom rectifiers, UPS systems.
4. RF/Wireless Infrastructure
Challenge: 5G mMIMO antennas demand low thermal noise.
Solution: Copper-core hybrids with RF-optimized dielectrics:
Phase stability ±0.1° over temperature
PIM distortion <-160dBc
Applications: Base station power amplifiers, radar systems.
UltraTherm™ Copper Core PCBs deliver revolutionary thermal performance for power-dense applications. By combining pure copper substrates with precision customized services and full EMS support, we enable next-gen reliability in LED, automotive, and industrial systems. Visit www.me-pcb.com to leverage our Copper Based PCB expertise for your mission-critical designs.
The core structure comprises three optimized layers:
Copper Substrate (Base Layer): 99.8% pure copper for maximum heat transfer.
Dielectric Insulation: Ceramic-filled polymer layer (0.1–0.3 mm) withstanding >3kV breakdown voltage.
Circuit Layer: High-current copper traces (1–20 oz) for power integrity.
Double-Sided Copper Core PCB Solutions for Automotive Manufacturing Automation
Our customized services allow engineers to specify substrate thickness, dielectric properties, and surface finishes (ENIG/HASL/Immersion Silver). For complex projects, we offer Copper Based hybrid designs integrating FR4 sections for signal control. As a full-service EMS provider, we support every phase – from thermal simulation and DFM analysis to automated assembly and functional testing.
Copper Core PCBs excel in environments where thermal cycling (e.g., -50°C to +150°C) causes conventional PCBs to delaminate. The copper core’s low CTE (16–18 ppm/°C) closely matches ceramic components, reducing solder joint stress. Applications include:
High-brightness LED arrays (1000W/m²+)
EV battery management systems
RF power amplifiers (5G/radar)
Industrial motor drives
Superior Thermal Management
Copper’s thermal conductivity (385 W/mK) is 2x higher than aluminum, slashing hotspot temperatures by 30–50°C. This prevents LED lumen decay, IGBT derating, and electrolytic capacitor drying – critical for >100,000-hour lifespans.
Material Excellence
High Purity Copper: Oxygen-free copper (C10100/C10200) minimizes grain boundaries for uniform heat spreading.
Military-Grade Dielectrics: Thermal resistance as low as 0.15°C-in²/W (vs. 1.0+ for standard MCPCBs).
Mechanical Resilience: Copper’s tensile strength (210 MPa) withstands vibration/shock in automotive/aerospace.
Electrical Performance
Low-impedance power planes enable 500A+ current delivery.
RF-friendly substrates with Dk=3.0±0.1 up to 10 GHz.
Manufacturing Precision
Laser-drilled micro-vias (<100μm) for HDI designs.
±0.05mm layer-to-layer registration.
UL 94 V-0 flame-rated options.
Meidear PCB positions itself as an end-to-end PCB solutions provider specializing in high-performance metal-core boards. Key observations:
Core Competencies:
Metal Core PCB Focus: Heavy emphasis on Copper-based PCBs and aluminum substrates for LED, power electronics.
Vertical Integration: Offers design → fabrication → component sourcing → assembly (EMS) under one roof.
Customization Strength: Highlights customized services for unusual shapes, hybrid materials, and thermal solutions.
Content Strategy:
Technical blogs address thermal design challenges (e.g., "Solving LED Thermal Runaway").
Case studies target automotive/industrial clients.
Lacks detailed copper PCB datasheets – a missed opportunity for engineers.
Market Positioning:
Targets mid/high-volume B2B clients (min. order 50–100pcs).
Strong Chinese manufacturing base with global EMS support.
Could enhance value by adding:
Thermal simulation reports
Comparative aluminum vs. copper performance data
RoHS 3.0/REACH compliance documentation
1. High-Power LED Systems
Challenge: 1000W COB LEDs generate >150°C junction temperatures.
Solution: UltraTherm™ Copper Core PCBs reduce thermal resistance to 0.25°C/W, enabling:
20% higher luminous efficiency
50% longer lifespan vs. aluminum MCPCBs
Applications: Stadium lighting, horticultural grow lights, automotive headlamps.
2. Electric Vehicle Power Electronics
Challenge: IGBT inverters in EVs produce 500W/cm² heat flux.
Solution: Direct-bonded copper (DBC) substrates on Copper-based PCBs achieve:
40°C lower operating temperatures
15% higher power density
Applications: OBC chargers, traction motor controllers.
3. Industrial Power Supplies
Challenge: Server PSUs require 99.995% uptime at 80+ Amps.
Solution: 3.0mm Copper Core PCBs with 20oz copper layers:
Handle 120A continuous current
Survive 100,000+ thermal cycles
Applications: Telecom rectifiers, UPS systems.
4. RF/Wireless Infrastructure
Challenge: 5G mMIMO antennas demand low thermal noise.
Solution: Copper-core hybrids with RF-optimized dielectrics:
Phase stability ±0.1° over temperature
PIM distortion <-160dBc
Applications: Base station power amplifiers, radar systems.
UltraTherm™ Copper Core PCBs deliver revolutionary thermal performance for power-dense applications. By combining pure copper substrates with precision customized services and full EMS support, we enable next-gen reliability in LED, automotive, and industrial systems. Visit www.me-pcb.com to leverage our Copper Based PCB expertise for your mission-critical designs.
